Hybrid Analysis of Tool Geometry and Process Noise in Fine Blanking through Simulation and Experiment

Abstract:

In fine blanking, a mass production process for safety-critical components, a discrepancy exists between deterministic modeling approaches and the stochastic nature of real-world measurements, often termed process noise. This work combines Finite Element Method simulations with data from industrial-scale fine blanking experiments, featuring long stroke series across multiple coils with systematically varied die clearances. The analysis shows a strong correlation between force curve characteristics and the formation of tears, a relationship that holds across all tested geometries. In contrast, only weak and inconsistent correlations were found between the force signal and the resulting die roll. This weakness is explained by the finding that multiple physical effects, such as material strength and friction, have competing influences on die roll that are not separable in the single force signal. These results demonstrate that the utility of the force signal for quality prediction is highly dependent on the tool geometry, providing a basis for more reliable tool design strategies in fine blanking.

• Periodical: Solid State Phenomena (Volume 389)
• Pages: 305-318
• DOI: https://doi.org/10.4028/p-k95d4N
• Online since: April 2026
• Authors: Daria Gelbich*, Frank Schweinshaupt, Thomas Stoel, Philipp Niemietz, Tim Herrig, Thomas Bergs
• Keywords: FEM Simulation, Fine Blanking, Process Noise, Tool Geometry

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